Peugeot Django 150 Workshop Manual

Quality department

After-Sales

WORKSHOP MANUAL

-

TABLE OF CONTENTS

1

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

TABLE OF CONTENTS

TABLE OF CONTENTS.....................................................................................................................................1

PRODUCTS DANGER SYMBOLS USED.........................................................................................................4

CHARACTERISTICS.........................................................................................................................................6

Engine........................................................................................................................................................6

Capacities ..................................................................................................................................................6

Chassis ......................................................................................................................................................7

Dimensions and weight..............................................................................................................................7

Tyres ..........................................................................................................................................................7

Brakes........................................................................................................................................................8

SERVICE SCHEDULE AND COMMISSIONING...............................................................................................9

Battery preparation ..................................................................................................................................10

Installing the battery.................................................................................................................................11

New machine preparation........................................................................................................................11

Electricity..................................................................................................................................................11

SPECIAL IMPORTANT POINTS .....................................................................................................................12

TIGHTENING TORQUES ................................................................................................................................13

Engine part...............................................................................................................................................13

Body panels.............................................................................................................................................13

Cycle part.................................................................................................................................................14

Standard...................................................................................................................................................14

SPECIAL TOOLS ............................................................................................................................................15

STANDARD TOOLS........................................................................................................................................16

LOCATION OF COMPONENTS......................................................................................................................17

BODY PANELS ...............................................................................................................................................18

Location of body components ..................................................................................................................18

Description ...............................................................................................................................................18

Body component sequence of disassembly.............................................................................................19

Removal of the passenger's saddle.........................................................................................................20

Removal of the storage compartment......................................................................................................20

Removal of the battery holder..................................................................................................................20

Remove the central fairing under the saddle ...........................................................................................21

Removal of the central cover panel..........................................................................................................21

Removal of a lower RH or LH side fairing................................................................................................21

TABLE OF CONTENTS

2

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Removal of the grab handles...................................................................................................................22

Removal of the upper side fairing assembly............................................................................................23

Removal of the front shield panel.............................................................................................................23

Removal of the head light fairing .............................................................................................................25

Removal of the speedometer fairing........................................................................................................26

Removal of the footboard.........................................................................................................................26

Removal of the rear shield panel .............................................................................................................27

Removal of the door-locking system........................................................................................................27

Removal of a RH or LH door....................................................................................................................28

Removal of the RH or LH under body panel............................................................................................28

Removal of the front mudguard ...............................................................................................................29

Removal of the dirt shield ........................................................................................................................30

SERVICE OPERATIONS.................................................................................................................................31

Empty the oil from the engine ..................................................................................................................31

Draining the relay box ..............................................................................................................................32

Replacing the air filter with transmission maintenance.....................................................................................33

Reassembly.......................................................................................................................................................33

Replacing the air filter without transmission maintenance ................................................................................33

Reassembly.......................................................................................................................................................34

Removal of the spark plug .......................................................................................................................34

Idle setting................................................................................................................................................35

Removal of the primary transmission cover.............................................................................................36

Removal of the starter system...........................................................................................................................36

Fitting the starter system...................................................................................................................................38

Removal of the transmission air filter ................................................................................................................38

Removal of the drive pulley......................................................................................................................39

Removal of the driven pulley....................................................................................................................39

Changing the drive pulley bearings..........................................................................................................40

Checking the drive belt ............................................................................................................................40

Checking the thickness of the clutch linings ............................................................................................41

Removal of the clutch lining assembly.....................................................................................................41

Refitting the clutch lining assembly..........................................................................................................42

Installing the primary drive.......................................................................................................................43

Installing the valve clearance...................................................................................................................44

Checking the valve clearance..................................................................................................................46

Changing the fuel filter.............................................................................................................................46

Integral braking ........................................................................................................................................47

Brake pad wear........................................................................................................................................47

Front brake........................................................................................................................................................47

Rear brake.........................................................................................................................................................48

TABLE OF CONTENTS

3

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Replacing the brake pads........................................................................................................................48

Front brake........................................................................................................................................................48

Rear brake.........................................................................................................................................................49

Bleeding the integral circuit......................................................................................................................50

Draining the main brake circuit..........................................................................................................................50

Bleeding the emergency system......................................................................................................52

Conventional braking ...............................................................................................................................54

Brake pad wear........................................................................................................................................54

Front brake........................................................................................................................................................54

Rear brake.........................................................................................................................................................55

Replacing the brake pads........................................................................................................................55

Front brake........................................................................................................................................................55

Rear brake.........................................................................................................................................................56

Draining the rear brake circuit:.........................................................................................................57

Draining the front brake circuit:........................................................................................................58

Checking the brake fluid level..................................................................................................................59

Draining the front fork ..............................................................................................................................60

STEERING/FORK............................................................................................................................................61

Changing the front fork seals...................................................................................................................61

The fork and its components.............................................................................................................................64

Reassembly.......................................................................................................................................................65

Removal of the fork..................................................................................................................................67

Replacing the bearings of the steering system........................................................................................69

Steering headset cups.......................................................................................................................................69

Steering cone ....................................................................................................................................................70

Installing the fork......................................................................................................................................70

FUEL SYSTEM................................................................................................................................................72

Removal of the fuel gauge.......................................................................................................................72

Fuel gauge check.....................................................................................................................................72

Removal of the fuel pump........................................................................................................................72

ELECTRICITY..................................................................................................................................................74

Ignition principle schematic/Carburetor heater/Battery charge circuit......................................................74

Regulator/Temperature control unit/Starter motor relay/CDI unit/Starter resistor.....................................75

Checking the ignition system...................................................................................................................75

Checking the carburettor heating circuit ..................................................................................................76

Checking the starter circuit.......................................................................................................................76

Checking the indicators............................................................................................................................77

Checking the red light, the stop light and the side light............................................................................77

POWER UNIT..................................................................................................................................................78

Removal of the power unit .......................................................................................................................78

PRODUCTS DANGER SYMBOLS USED

4

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.

Möbius band Recyclable.

Means that the product or the package

can be recycled. However, this does not

guarantee that the product will be

recycled.

Irritant

The product can irritate the

skin, eyes and respiratory

organs.

Avoid contact with skin and clothes. Wear

gloves, safety goggles and cotton

overalls.. Do not breath fumes. If in

contact, wash thoroughly with water.

Flammable The product is flammable.

Keep it away from flames or any heat

source (barbecue, radiator, heating, etc.).

Do not leave the product in the sun.

Corrosive

The product can damage living

tissues or other surfaces.

Avoid contact with skin and clothes. Wear

gloves, safety goggles and cotton

overalls.. Do not breath fumes.

Explosive

The product can explode under

certain circumstances (flame,

heat, impact, friction).

Avoid impacts, friction, sparks and heat.

Hazardous to

the environment

The product affects fauna and

flora. Do not dump it in

dustbins, sinks or in the

environment.

The ideal solution is to bring this product

to your nearest household waste recycling

centre.

Toxic

The product can seriously

affect health if it is inhaled,

ingested or in contact with skin.

Avoid direct contact with the body, even by

inhalation. If you feel unwell, seek medical

advice immediately.

Do not throw

away into a

garbage can

One of the product's

component is toxic and can be

hazardous to environment.

Example: Used batteries.

This symbol informs the consumer that the

used product shall not be thrown away into

a garbage can, but shall be brought back

to the merchant or dropped at a specific

collection point.

Compulsory

gloves

Operation that can be

dangerous for people.

People's safety can be seriously affected if

the recommendations are not fully

respected.

PRODUCTS DANGER SYMBOLS USED

5

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

People's safety

Operation that can be

dangerous for people.

People's safety can be seriously affected if

the recommendations are not fully

respected.

Important

Operation that can be

hazardous to the vehicle.

Indicate the specific procedures that shall

be followed in order not to damage the

vehicle.

Good operating

condition of the

vehicle

The operation must be carried

out in strict compliance with the

documents.

Serious damage to the vehicle and in

certain cases a cancellation of the

warranty can be involved if the

recommendations are not fully respected.

Note Operation that can be difficult.

Indicate a note which gives key

information to make the procedure easier.

Lubricate

Lubricate the parts to be

assembled.

Indicate the specific procedures that shall

be followed in order not to damage the

vehicle.

Grease

Grease the parts to be

assembled.

Indicate the specific procedures that shall

be followed in order not to damage the

vehicle.

Glue

Glue the parts to be

assembled.

Indicate the specific procedures that shall

be followed in order not to damage the

vehicle.

New part Use a new part.

Indicate the specific procedures that shall

be followed in order not to damage the

vehicle.

GLUE

CHARACTERISTICS

6

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

CHARACTERISTICS

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Engine

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Capacities

125 cc 150 cc

Marking XS1P52QMI-3B XS1P57QMJ-2B

Type

4-stroke single-cylinder

4 valves per cylinder with chain driven overhead camshaft

Cooling By a circulation of forced air by means of a turbine on the flywheel magneto

Bore x stroke 52.4 x 57.8 mm 57.4 x 58.2 mm

Cubic capacity 124.6 cc 150.6 cc

Max. power output 7.5 kW at 8500 rpm 8.3 kW at 8000 rpm

Max. torque rating 8.9 Nm at 7000 rpm 11 Nm at 6000 rpm

Compression

Compression ratio 10,6

±0.2

:1 Compression ratio 10,4

±0.2

:1

Compression ratio

11.4 bars at 700 rpm

7 bars Minimum.

Lubrication Trochoid pump driven by a chain from the crankshaft

Transmission By 2 variable pulleys and V-type belt

Clutch Centrifugal automatic

Exhaust Catalytic

Spark plug

NGK CR7HSA

Electrode gap: 0.7 - 0.8mm

Magneto flywheel 80W

Fuel supply Deni DPD24J carburettor

Standards Euro3

Crankcase

0.95 L

(0.7 L at oïl change)

SAE 5W40 Synthetic

Minimum grade: API SJ

Relay box

0.18 L SAE 80W90 (0.17 L at oïl change)

Minimum grade: API GL4

Fuel tank

8.5 L

Unleaded 95 or 98

Fork oil 0.092 L per tube SAE 10W.

CHARACTERISTICS

7

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Chassis

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Dimensions and weight

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Tyres

Chassis Steel tube

Front suspension

32 mm Ø telescopic front fork

Travel: 85mm

Rear suspension Combined spring and hydraulically-damped shock absorber Travel: 88 mm

Overall length

1925 mm

Width at handlebar

710 mm

Height. (without rear-

view mirrors)

1190 mm

Wheelbase 1350 mm

Ground clearance 110 mm

Saddle height 770 mm

Unladen weight

129 kg

Front wheel rims 3"x12 inch aluminium alloy

Front tyre 120/70 - 12

Front tyre pressure 1.8 bars

Rear wheel rim 3"x12 inch aluminium alloy

Rear tyre 120/70 - 12

Rear tyre pressure 2 bars

CHARACTERISTICS

8

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

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Brakes

Version Conventional braking Integral braking

Front brake Single disc type, hydraulic control

Disc diameter and

thickness

200 mm - 3.5mm

Mini. thickness: 3 mm

Front caliper

Floating calliper equipped with

2 pistons

Floating calliper equipped with

3 pistons

Rear brake Single disc type, hydraulic control

Disc diameter and

thickness

196 mm - 4 mm

Mini. thickness: 3.5 mm

190 mm - 4 mm

Mini. thickness: 3.5 mm

Rear caliper Fixed calliper with 2 pistons

Floating caliper equipped with one

piston

Chassis markings

1. VIN number 2. Manufacturer's plate

Engine marking

3. Engine number

xxxxxxxxxxxxxxxx

1

2

XXXXXX

*XXXXXXX

XX

*

3

SERVICE SCHEDULE AND COMMISSIONING

9

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters

SERVICE SCHEDULE AND COMMISSIONING

Heavy duty servicing is for vehicles used under "harsh" conditions: door-to-door deliveries, intensive

urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.

Normal servicing in km 500 5000 10000 15000 20000 25000

Extensive servicing in km

a

a.Perform these maintenance operations if the vehicle is used in severe conditions: areas that are damp, dusty, or have high

températures, urban use only, etc

500 2500 5000 7500 10000 12500

Minimum servicing

1months 12months 24months 36months 48months 60months

To be checked at each service

Steering column play. V V V V V V

Wheel bearing play. C C C C C C

Throttle cable play. V V V V V V

Operation of electrical equipment. V V V V V V

Condition of front and rear brake hydraulic controls. V V V V V V

Brake fluid level. V V V V V V

Brake pad wear. C C C C C C

Condition of petrol pipes. C C C C C C

Tyre condition, pressure and wear. C C C C C C

Condition of the front suspension. Condition of the rear suspension.

V V V V V V

Battery charge. V V V V V V

Engine oil level.

Every 1000 km

Headlight height adjustment. V V V V V V

Tightness of nuts and bolts. V V V V V V

Overall operation. Road test. V V V V V V

Service operations

Spark plug. R R

Air filter.

R

a

R

a

R

a

Intake silencer drain. N N N N N

Drive pulley rollers and guides/Flange wear. C C

Driven pulley caged needle bearing. G G

Transmission belt. R R

Kick starter mechanism. G G

Valve clearances. V V V V V

Setting the carburettor. V V

Joints. (Central stand. Lateral stand) G G G G G

Petrol filter. R

Engine oil (+ clean strainer). R R R R R R

Relay box oil. R R R R R R

Fork oil. R

Petrol pipe.

R Once every 5 years

Brake fluid.

R Once every 2 years

Servicing time in tenths of an hour (0.5 h = 30 min)

Reception and Treatment 0.1 0.1 0.1 0.1 0.1 0.1

Django 125/150cc 0.9 1.9 2.3 1.9 3.3 1.9

V: Check, clean, adjust. R: Change. G: Check, clean, lubricate. C: Inspect and change if necessary. N: Clean.

After 20000 km, resume the service schedule again from 5000 km.

SERVICE SCHEDULE AND COMMISSIONING

10

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Battery preparation

Battery preparation:

- Remove the battery's filler protector.

- Remove the strip of caps (1) from the

electrolyte bottle, which will be used as battery

caps (2).

- Place the electrolyte bottle upside down with

the 6 sealed zones in line with the 6 battery filler

holes.

- Press downwards to pierce the bottle's seal.

- Air bubbles must go up into the bottle.

- Tap on the bottle to help the air bubbles go up.

- Once the battery is filled with electrolyte,

remove the bottle.

- Leave the battery to stand for around half an

hour.

- Fit the strip of caps (1) over the battery's filler

holes.

Battery charge:

Once it is filled with electrolyte, a new battery is

charged up to approximately 80%.

The battery must be charged before being used

for the first time. If it is not charged in this way a

loss of 20% of its maximum nominal capacity and

30% of its life expectance will be permanent.

You must absolutely use a battery

charger provided with a charge regulator

which is suited to small capacities.

See documentation: Workshop tools

N° 2.

The battery's maximum charging

current is equal to 1 tenth of its capacity.

- Charge the battery for 5 to 10 hours.

- Leave the battery to stand for around half an

hour.

Never remove the battery's strip of caps, and never add water or electrolyte into the battery.

2

1

T

E

S

T

SERVICE SCHEDULE AND COMMISSIONING

11

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Installing the battery

- Fit the battery.

- Connect the red wire lug to the battery's +

terminal, and the green wire lug to the battery's

- terminal.

- Fit the battery cover, ensuring it is the right way

round. The vehicle's cubic capacity must be

visible from the outside.

- 2 plastic screws.

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New machine preparation

- See the new vehicle preparation sheet.

- Check the wheel nuts are tight.

- Check nuts and bolts are tight.

- Check brake adjustment and efficiency.

- Check the tyre pressures cold.

- Check operation of the lights, flashers, horn, and brake light.

- Check the different warning lights work.

- Carry out a road test.

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Electricity

All components of the electrical system are powered with 12 volts DC.

The battery must not be disconnected while the engine is running and the voltage must be at least

8.5 volts for the ECU to function and enable engine starting.

125/151CC

SPECIAL IMPORTANT POINTS

12

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SPECIAL IMPORTANT POINTS

This engine is designed to run on 95 or 98 unleaded fuel only.

Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc.

The clips are specific, they must always be changed each time they are removed and replaced

with new genuine parts clips.

Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or

sparks.

Before carrying out any work, leave the engine to cool for at least 2 hours.

TIGHTENING TORQUES

13

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TIGHTENING TORQUES

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Engine part

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Body panels

Quantity Dimension

Tightening torque

125/151 cc

Spark plug 1 M10-1.5 10 to 12Nm

Engine drain plug 1 M12 35 to 45Nm

Screen 1 M30 10 to 20Nm

Cylinder head

Nut Ø8 mm

Screw Ø6 mm

4

2

M8-1.25

M6-1.0

18 to 22Nm

7 to 11 Nm

Cylinder head cover 4 M6-1.0 8 to 12 Nm

Camshaft gear 2 M6-1.0 10 to 15Nm

Camshaft stopper plate 1 M6-1.0 10 to 15Nm

Automatic tensioner 2 M5-0.8 7 to 11 Nm

Automatic tensioner plug 2 M6-1.0 8 to 12 Nm

Camshaft gear 1 M6-1.0 8 to 12 Nm

Chain tensioner 1 M6-1.0 8 to 12 Nm

Inlet manifold 2 M6-1.0 8 to 12 Nm

Cylinder casings 2 M6-1.0 8 to 12 Nm

RH casing cover 10 M6-1.0 7 to 11 Nm

Freewheel 1 M22 90 to 100 Nm

Oil pump 2 M6-1.0 8 to 12 Nm

Anti-splash plate 2 M6-1.0 8 to 12 Nm

Transmission cover 8 M6-1.0 8 to 12 Nm

Relay box cover 7 M8-1.25 26 to 30Nm

Relay box drain plug 1 M8-1.25 10 to 15Nm

Relay box filler cap 1 M8-1.25 10 to 15Nm

Starter motor 2 M6-1.0 7 to 11 Nm

Rotor 1 M12 50 to 60Nm

Turbine 4 M6-1.0 8 to 12 Nm

Stator 2 M6-1.0 8 to 12 Nm

Engine speed sensor 2 M5-0.8 4 to 6 Nm

Drive pulley 1 M12 55 to 60Nm

Driven pulley 1 M12 50 to 60Nm

Clutch plate and shoes 1 M28 55 to 60Nm

Front mudguard

8 to 10 Nm

Handlebar cover

1 to 2 Nm

Front shield panels

1 to 2 Nm

Rear shield

1 to 2 Nm

Bottom panel

6 to 8 Nm

Floor panel

8 to 10 Nm

Saddle storage compartment

8 to 10 Nm

Rear body panels

1 to 2 Nm

Grab handle

20 to 25 Nm

TIGHTENING TORQUES

14

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Cycle part

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Standard

Front wheel spindle

60 to 70 Nm

Wheel hub pin

100 to 120 Nm

Rear wheel bolt

27 to 32 Nm

Engine/linkrod connecting pin

52 to 62 Nm

Linkrod/chassis connecting pin

52 to 62 Nm

Shock absorber top mount

43 to 50 Nm

Shock absorber bottom mount

20 to 25 Nm

Exhaust to cylinder head mounting nut

20 to 25 Nm

Exhaust to casing mounting bolt

20 to 25 Nm

Steering nut 1 (in 2 operations)

38 to 42 Nm/15 to 19Nm

Steering nut2

Hand tightened

Steering locknut

70 to 85 Nm

Front brake caliper

27 to 32 Nm

Brake pad pins

12 to 18 Nm

Front brake disc

27 to 32 Nm

Rear brake caliper

27 to 32 Nm

Rear brake disc

27 to 32 Nm

Brake unions

27 to 35 Nm

Handle bar

35 to 45 Nm

Fork tube

25 to 30 Nm

Fork tube cap

25 to 30 Nm

Nut and bolt 5 mm diameter 5 Nm

Nut and bolt 6 mm diameter 10 Nm

Nut and bolt 8 mm diameter 22 Nm

Nut and bolt 10 mm diameter 35 Nm

Nut and bolt 12 mm diameter 55 Nm

SPECIAL TOOLS

15

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SPECIAL TOOLS

(*) New or modified tool

Tool N° Designation Used with Tool N° Designation Used with

752237

Adjustable

pin wrench

757860 Steering tool

752361

39 mm pipe

casing seal

drift

758008

Clutch

compression

tool

801682

759788

Steeing head

cup push tool

801682

Spacer

adaptor

758008

755996 Hose clamp

STANDARD TOOLS

16

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STANDARD TOOLS

Slide calipers Set of shims

Heat gun

Automatic resetting type

torque wrench

5 to 25 Nm

Type: Facom R.306A25

Intertia type extractor

tool for bearings from

6 to 18 mm

Type: Facom U.49PJ3

Automatic resetting type

torque wrench

10 to 50 Nm

Type: Facom J.208A50

Multimeter

Automatic resetting type

torque wrench

40 to 200 Nm

Type: Facom S.208A200

Fork seal insertion kit

Type: Marolotest 601055

Wrenches with

interchangeable end

fittings for valve

clearance adjustment

Type: Marolotest 500140

OFF

VDC

VAC

Ω

20 m

200 m

DC

10A

V

Ω

COM

mA

Ω

LOCATION OF COMPONENTS

17

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LOCATION OF COMPONENTS

1. Starter motor relay

2. Starter resistor

3. Regulator

4. CDI unit

5. Temperature control unit

6. HT coil

7. Outside temperature sensor

8. Speed sensor

9. 12-volt plug

10.Ignition sensor

11.Instrument panel

12.Fuses

13.Battery

14.Choke

15.Carburetor heater

16.Kickstand contact switch

17.Fuel gauge

18.Horn

FB

6

43

7

9

2

10

5

1

8

16

14

17

12

13

15

11

18

BODY PANELS

18

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BODY PANELS

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Location of body components

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Description

1. Front shield panel

2. Front mudguard

3. Mudguard

4. Front wheel

5. Bottom panel

6. Floor panel

7. Central panel

8. Lower side fairing

9. Upper side fairing

10.Rear central fairing

11.Grab handle

12.Battery holder

13.Passenger backseat

14.Saddle storage compartment

15.Rider saddle

16.Rear shield

17.Counter panel

18.Headlight fairing

19.Sheath guide

FB

4

3

7

9

2

10

1

8

13

17

16

11

5

12

14

18

6

15

19

BODY PANELS

19

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Body component sequence of disassembly

1. Front shield panel *

2. Front mudguard

3. Mudguard

4. Front wheel *

5. Bottom panel

6. Floor panel

7. Central panel *

8. Lower side fairing

9. Upper side fairing

10.Rear central fairing *

11.Grab handle

12.Battery holder

13.Passenger backseat *

14.Saddle storage compartment

15.Rider saddle

16.Rear shield

17.Handlebar rear fairing

18.Handlebar front fairing

19.Sheath guide

* This item may be removed on its own.

8

14

11

12

2

3

15

9

7*13* 10* 1*

18

17

19

16

6

4*

5

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